Intake Manifold

Removal

1. WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

1. Remove the following items:
   1. Refer to: Fuel Rail (303-04A Fuel Charging and Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
      
   2. Refer to: Generator - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (414-02 Generator and Regulator, Removal and Installation).
      

Installation

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

   NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.

1. Torque :
     Stage 1:  6 Nm
     Stage 2:  18 Nm

1. Torque : 9 Nm

1. NOTE: Lubricate the O-ring seal with clean engine oil.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
   Torque : 4 Nm

1. Install the following items:
   1. Refer to: Generator - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (414-02 Generator and Regulator, Removal and Installation).
      
   2. Refer to: Fuel Rail (303-04A Fuel Charging and Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
      

1. Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

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